Process optimisation thanks to smart modelling

Finite element analysis helps to reduce development time and limits technical and budgetary risks. The acquired know-how on modelling rolling processes allows anticipating difficulties or proposing modifications whenever new compositions need to be processed.

Finite element analysis (FEA) is widely used in multiple domains of scientific research and successfully applied in many customer applications. Also in the support and development of bar rolling at OCAS, FEA proved to be a valuable tool.

Finite element simulations have been applied to optimize the rolling procedure in rod and wire rolling applications. Analysis of the forming behaviour of the rod or wire in each rolling step is possible through creation of parametric models of the process. The complex interaction of material properties, process parameters and the effect of the rolling geometry can now be studied and understood, returning valuable insight in the rolling mechanisms. As a result, definition of the rolling scheme, i.e. the complete sequence of the consecutive reductions (rolling shapes) of the intermediate passes, the temperature during each pass and various other process conditions, can be defined precisely.

FEA allows to reduce development time and limit technical and budgetary risks. Analysis of the rolling system can be further expanded to the scientific level, beyond the practical methodology as described earlier. The base model may then be extended with advanced material models that take into account e.g. the effect of strain rate, deformation path and heat exchange between the bar material and rolls in order to support the experimental findings on strain distribution and crystallographic structure.


“Our 3D modelling of the rolling process has proven to be a valuable tool during rolling campaigns”.

Kris Hertschap, Research engineer Electromechanical engineering team, OCAS